WO2006041118A1 - Procede de production d'agglomere poreux, materiau de moulage d'agglomere poreux et agglomere poreux associe - Google Patents

Procede de production d'agglomere poreux, materiau de moulage d'agglomere poreux et agglomere poreux associe Download PDF

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Publication number
WO2006041118A1
WO2006041118A1 PCT/JP2005/018850 JP2005018850W WO2006041118A1 WO 2006041118 A1 WO2006041118 A1 WO 2006041118A1 JP 2005018850 W JP2005018850 W JP 2005018850W WO 2006041118 A1 WO2006041118 A1 WO 2006041118A1
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WO
WIPO (PCT)
Prior art keywords
forming material
binder
disappearance
pore
temperature
Prior art date
Application number
PCT/JP2005/018850
Other languages
English (en)
Japanese (ja)
Inventor
Shigeo Tanaka
Shinji Ishida
Kazuaki Nishiyabu
Original Assignee
Taisei Kogyo Co., Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Taisei Kogyo Co., Ltd. filed Critical Taisei Kogyo Co., Ltd.
Priority to EP05793657.7A priority Critical patent/EP1808243B1/fr
Priority to ES05793657T priority patent/ES2738003T3/es
Priority to US11/665,017 priority patent/US9272333B2/en
Priority to JP2006540963A priority patent/JP5503838B2/ja
Publication of WO2006041118A1 publication Critical patent/WO2006041118A1/fr
Priority to US14/962,466 priority patent/US20160090327A1/en
Priority to US16/545,646 priority patent/US11819917B2/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1017—Multiple heating or additional steps
    • B22F3/1021—Removal of binder or filler
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/04—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by dissolving-out added substances
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/0081—Uses not provided for elsewhere in C04B2111/00 as catalysts or catalyst carriers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00844—Uses not provided for elsewhere in C04B2111/00 for electronic applications
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/268—Monolayer with structurally defined element

Definitions

  • the present invention relates to a method for producing a porous sintered body, a porous sintered molding material, and a porous sintered body. Specifically, the present invention relates to a method for producing a porous sintered body that can form a porous sintered body having a high porosity with high accuracy.
  • Products having a porous sintered body with a large number of pores inside are provided. These products include filters, chemical reaction catalysts, electrodes, and heat exchange. Further, there is also provided a bearing material that is used as a bearing material by retaining lubricating oil or the like in the holes.
  • porous sintered body As a method for producing the porous sintered body, a forging method, a foaming method, a plating method and the like are known. In addition, the powdery sintered material and the pore forming material that disappears by heating are mixed and molded, and then the pore forming material disappears by heating to form pores.
  • a space holder method in which a porous sintered body is formed by heating and sintering can also be used.
  • Japanese Laid-Open Patent Publication No. 2001-2271101 discloses a method for manufacturing a sintered body using the space holder method.
  • a molded body is molded using a composition comprising a raw material powder, an organic binder, and a pore-forming material having a decomposition start temperature higher than the decomposition start temperature of the organic binder.
  • a first degreasing step for removing the organic binder to obtain a first degreased body a second degreasing step for removing the pore forming material to obtain a second degreased body, and the first degreasing body.
  • a method for producing a sintered body is disclosed.
  • the pore forming material generally has a larger size than the binder material sintered material particles.
  • the sintered material particles and the binder are filled so as to surround the pore forming material. That is, in the invention described in the above patent document, after the binder disappears, the sintered material particles are supported by the pore forming material and are present around the pore forming material. Yes. If the pore forming material is eliminated from this state, the sintered material particles around the pore forming material fall into the space where the pore forming material has disappeared, or the walls between the pores are deformed. Cheap. As a result, it is difficult to obtain a sintered body having a required size and shape as soon as the molded body is deformed in the degreasing process.
  • a porous sintered body has been developed in which a functional particle material having a function such as a catalyst is mixed with a sintered material, molded and sintered, and a new function is added.
  • a functional particle material having a function such as a catalyst
  • a new function is added.
  • a sintered body produced by sintering a sintered material mixed with a functional particle material it is difficult to expose only a part of the functional particle material on the inner surface of the pores. For this reason, it was not possible to exert an effect commensurate with the amount of the functional material particle material. Therefore, in order to exert the effect of the functional raw particle material, a large amount of functional particle material is required. For example, it is difficult to employ an expensive material such as platinum.
  • the present invention has been devised in order to solve the above-mentioned problems, and can solve the above-mentioned problems in the degreasing process to produce a highly accurate porous sintered body and has an unprecedented function.
  • a porous sintered body can be produced.
  • the invention described in claim 1 of the present application includes a molding process for molding a sintered molding material including a binder, a sinterable powder material, and a pore-forming material into a predetermined shape, and the molding process.
  • a porous sintered body comprising a degreasing step for removing the binder in addition to the strength of the molded body obtained as described above, and a sintering step for sintering the degreased molded body after the degreasing step to form a sintered body.
  • the binder is configured to include a component that is higher than the disappearance temperature of the pore-forming material and disappears at a temperature, and a part of the binder remains in the degreasing step. The above-mentioned hole forming material disappears.
  • the pore forming material is first disappeared while a part of the binder remains.
  • the binder in the present application is a component other than the sintered material and the pore forming material, and includes all components that are included in the molded body after molding and can exhibit a shape retaining function in the degreasing process.
  • the binder that remains is combined with the sintered material around the pore forming material to improve the shape retention in the disappearance process of the pore forming material.
  • the amount of binder necessary to form the gap necessary to eliminate the above-mentioned pore-forming material does not remain in the binder component until the pore-forming material disappears. And disappear before the pore forming material.
  • the sintered material particles around the pore forming material are not collapsed, and it is possible to form pores with high shape and dimensional accuracy. Further, by leaving a part of the binder, the strength of the molded body after the formation of the pores is increased, and intermediate processing such as the above-described filling process of the functional raw particles is also possible.
  • the kind of the sintered material in the present invention is not particularly limited. Metal powder, ceramic powder, or a mixture of these can be used as the sintered powder material.
  • the particle size of the powder is not particularly limited.
  • the amount of the remaining binder is not particularly limited, and the blending ratio is set depending on the size of the pore forming material, the size of the sintered material particles, and the presence or absence of intermediate processing after the formation of the pores. be able to.
  • the blending ratio of the binder to the entire injection molding material is preferably set in the range of 8% to 40% by volume. If it is 8% by volume or less, the flow in the mold will be poor and the accuracy of the molded product will be reduced. On the other hand, when 40 volume% or more is blended, the molded body undergoes large shrinkage deformation during degreasing.
  • the amount of the binder to be left is preferably set to an amount that can ensure the strength of the molded body at least in the process of disappearance of the pore forming material. That is, in the degreasing step, it is preferable to eliminate the pore forming material while leaving a binder that does not deform the molded body.
  • the mode in which the pore forming material disappears is not particularly limited, and includes combustion, decomposition, evaporation, and the like.
  • a certain amount of the binder is eliminated in order to secure a path or gap in which the pore-forming material disappears when the pore-forming material starts to disappear. Furthermore, it is preferable to set so that the disappearance path is formed according to the disappearance mode of the pore forming material, for example, the disappearance speed and the disappearance amount. In addition, when intermediate processing is performed after the formation of holes, it is preferable to leave a binder component sufficient to ensure strength according to the type of intermediate processing when the hole forming material disappears.
  • the invention described in claim 2 of the present application is characterized in that the binder is lower than the disappearance temperature of the pore-forming material!
  • the low-temperature disappearance component disappears at the degreasing temperature, and the disappearance temperature of the pore-forming material.
  • a high temperature disappearance component that disappears at a higher degreasing temperature, and the degreasing step includes a step until the low temperature disappearance component starts disappearing and the pore forming material starts disappearing. 1 degreasing process, the 2nd degreasing process until the said pore formation material lose
  • the low temperature disappearance component starts disappearing. As a result, a gap is formed for the disappearance of the pore forming material. Note that it is not necessary for all of the above-mentioned low temperature disappearance components to disappear before the disappearance of the above-mentioned pore forming material. It only has to disappear. Next, the temperature is increased and the pore forming material disappears. Until the pore-forming material disappears completely, Part or all of the high temperature disappearance component is left to improve the shape retention when the pore forming material disappears. In order to ensure shape retention, it is preferable to leave a considerable amount of binder corresponding to the form of the molded body after the pore forming material has completely disappeared.
  • the invention described in claim 3 of the present application is characterized in that, in the second degreasing step, the pore-forming material is a gap formed by eliminating the low temperature disappearance component! A part of the lost component disappears and disappears through a gap formed.
  • the low temperature disappearance component and the high temperature disappearance component can be selected based on the disappearance temperature of the pore forming material.
  • the low temperature disappearance component may be selected from those that start disappearing before the pore forming material starts disappearing.
  • the high temperature disappearance component may be selected such that at least a part of it remains even after the selected pore forming material has completely disappeared.
  • the low temperature disappearance component and the high temperature disappearance component can be selected based on the decomposition start temperature and decomposition end temperature of the material.
  • the invention of the present application is characterized in that when the pore-forming material disappears, the binder component remains to improve the shape retention, and the material is obtained only by the general decomposition start temperature and decomposition end temperature. Is not the one that will be selected.
  • the invention described in claim 4 of the present application is configured so that 0.1% to 5.0% by volume of the binder component is lost at the start of disappearance of the pore-forming material. It is.
  • the amount of the noda for forming the disappearance path varies depending on the pore forming material and the size of the sintered particles, but is preferably set to 0.1% by volume or more of the total amount of the binder. If the ratio is equal to or less than the above ratio, the disappearance path cannot be secured in the initial stage when the pore forming material starts disappearing, and after the pore forming material starts disappearing, pressure acts on the surrounding sintered material, Deformation is likely to occur.
  • the degreasing temperature in the above process is not particularly limited, but the above-mentioned required amount of vanida can be eliminated by maintaining the degreasing temperature at which the binder disappears and the pore forming material does not disappear for the required time. Can do.
  • the invention described in claim 5 of the present application is configured such that when the pore forming material disappears, 5 to 40% by volume of the binder component remains.
  • the binder component In order to ensure the strength of the pore inner wall, it is preferable to leave the binder component at 5% by volume or more when the pore-forming material is completely lost. If it is 5% by volume or less, there is an increased risk that the molded body will be deformed or the like after the void forming material disappears or disappears. On the other hand, if it is set so as to remain at 40% by volume or more, the loss of the pore forming material is inhibited, and the molded body may be stressed during the disappearance process. In addition, the degreasing time after disappearance of the pore forming material becomes longer.
  • the high temperature disappearance component is configured to include at least two binders having different disappearance temperatures, and the third degreasing step includes these erasing steps. This is performed by sequentially eliminating noinda components having different temperature loss.
  • At least two or more binders having different disappearance temperatures are sequentially eliminated after the pore-forming material has disappeared, so that the remaining binder can be smoothly eliminated without applying excessive stress to the molded body. Is possible. This makes it possible to produce a porous sintered body with a very high porosity of, for example, 50% to 80%.
  • the invention described in claim 7 of the present application includes an intermediate processing step of performing an intermediate processing on the intermediate degreased body after the second degreasing step.
  • the binder since the binder remains in the porous molded body after the second degreasing step, the strength required for intermediate processing can be ensured. Therefore, with porous body Various intermediate processes can be performed on the formed body. Note that it is preferable to leave the amount of the binder for ensuring the necessary strength depending on the processing method, etc., assuming that the intermediate addition is performed. In addition, the type of the intermediate processing is not particularly limited, and various mechanical forces such as plastic molding can be performed.
  • the intermediate degreased body that has finished the second degreasing step is used. It is possible to perform an additional material filling process in which a predetermined additional material is filled in a part or all of the holes.
  • the third degreasing step and the sintering step are performed, and the additional material is disposed on the inner surface of the hole. It is sintered integrally with the sintered material.
  • the additional material can be integrally sintered with the sintered body in a single sintering step.
  • the invention described in claim 10 of the present application performs the third degreasing step and the sintering step after finishing the additional material filling step, and holds the additional material in a freely movable manner in the pores.
  • ⁇ 3 ⁇ 4 Things.
  • the degreased body shrinks. Therefore, the size of the pores decreases with the shrinkage.
  • the present invention uses the above shrinkage to try to fix the attached calorie material that cannot be sintered in the air holes. For example, particles of a functional ceramic that does not sinter at the metal sintering temperature are held movably in the pores of the metal porous body, and the functions of the functional ceramic and the like are maximized through the pores. Can be used to
  • the mixing ratio of the pore forming material is set to 50% to 80% by volume of the sintered molding material.
  • the filling rate is about 74%.
  • the porosity can be increased to 80% by forming the pore forming material by applying pressure so as to deform it. It is also possible to increase the porosity by blending pore-forming materials with different sizes.
  • Various processing techniques can be employed as a method of forming the molded body according to the present invention.
  • press molding or extrusion molding can be employed.
  • the molding step can be performed by injection molding.
  • the invention described in claim 13 of the present application is a sintered molding material including a binder, a sinterable powder material, and a pore-forming material, wherein the binder includes the pore-forming material. It contains a low temperature disappearance component that disappears at a low temperature below the temperature at which it disappears, and a high temperature disappearance component that disappears at a temperature that is higher than the above-described pore forming material.
  • the binder contains 40 vol. It is comprised including% to 70% by volume.
  • the low temperature disappearance component and the high temperature disappearance component can be selected in accordance with the disappearance temperature of the pore forming material employed.
  • the mode of disappearance is not particularly limited, and includes combustion, decomposition, evaporation, and the like.
  • the low temperature disappearance component is 40% or less, the disappearance route of the pore forming material cannot be secured.
  • the blending ratio of the low temperature disappearance component is 70% by volume or more, the shape retention strength in the process of disappearance of the pore forming material is insufficient.
  • the low temperature disappearance component and the high temperature disappearance component do not have to be one component each. That is, the low temperature disappearance component is a concept that includes all components that disappear before the pore forming material disappears in the degreasing step. On the other hand, the high temperature disappearance component is a concept that includes all the blending components that are at least partially remaining and then disappear when the above-mentioned pore forming material disappears.
  • the invention described in claim 15 of the present application is configured such that the high temperature disappearance component includes at least two or more noda components that disappear at different disappearance temperatures after the void forming material disappears. It is a thing.
  • the invention described in claim 16 of the present application relates to a porous sintered molding material comprising 50 to 80% by volume of the pore forming material.
  • shape retention during molding can be improved, so that it is possible to blend 50 to 80% by volume of the pore forming material.
  • the invention described in claim 17 of the present application is a porous sintered body, and at least a part of the pores is not sintered at the sintering temperature of the sintered body due to shrinkage in the sintering process. A powdery material is held.
  • the invention described in claim 18 of the present application relates to a porous sintered body constituted by holding the powdery material movably in the pores.
  • FIG. 1 is a diagram schematically showing a cross-sectional structure of a molded body according to an embodiment.
  • FIG. 2 is a diagram schematically showing a cross-sectional structure of a molded body after the first degreasing step.
  • FIG. 3 is a diagram schematically showing a cross-sectional structure of a molded body after the second degreasing step.
  • ⁇ 4 A view schematically showing a cross-sectional structure of a molded body after the third degreasing step.
  • FIG. 5 is a diagram schematically showing a cross-sectional structure of a sintered body.
  • FIG. 6 is a flowchart showing a process of the present invention.
  • FIG. 7 is a diagram showing a state in which pore forming materials and binders are reduced during the degreasing process.
  • FIG. 8 is a diagram schematically showing a cross-sectional structure of a sintered body according to a second embodiment of the present application.
  • 316L is used as the pore-forming material, soot (polymethyl methacrylate) with an average particle size of 50 ⁇ m.
  • soot polymethyl methacrylate
  • binders Three types of binder components are used as binders: wax (composite wax of natural wax and synthetic wax), POM (polyacetal) and PP (polypropylene). These components are uniformly kneaded at the blending ratio shown in Table 1 to form an injection molding material.
  • the kind of metal powder as the sintering material is not particularly limited. If it can be sintered, other metal powders, ceramic powders, or a mixture of these selected materials may be used. Can do.
  • the average particle size of the metal powder is not particularly limited. So-called submicron particles of 1 ⁇ m or less can be used, and large powder particles of about 100 m can also be used. In order to enhance the sintering performance, it is preferably employed in the range of 1 to 30 / ⁇ ⁇ . In the case of producing a sintered body having a porosity of 50% or more, it is preferable to set the average particle size of the metal powder smaller than that of the pore forming material.
  • the blending amount of the metal powder is preferably set to 15 to 30% by volume of the entire force-kneaded product, which varies depending on the porosity. If the blending amount is less than 15% by volume, the amount of binder increases and the amount of shrinkage and deformation during degreasing and sintering increases. On the other hand, when it exceeds 30% by volume, fluidity is lowered and workability is lowered.
  • soot particles having an average particle size of 50 ⁇ m are used as the pore forming material.
  • the PMMA particles have an onset disappearance temperature of 240 ° C.
  • the disappearance temperature at which the compact strength is completely removed is 400 ° C.
  • the pore forming material a material that does not softly melt or melt at the time of kneading or injection molding is adopted. Further, in the present embodiment, a spherical granular material is adopted as the pore forming material, but various shapes such as a fiber shape and a rod shape can be adopted by a molding method.
  • the binder according to the present embodiment includes a binder A composed of a component having a disappearance temperature lower than the disappearance temperature of the pore forming material, and a higher disappearance temperature than the disappearance temperature of the pore formation material.
  • Binder B containing two components having the following is adopted.
  • the binder A is a wax component, and the disappearance start temperature is about 210 ° C, while the disappearance The temperature is 340 ° C.
  • Binder B is composed of POM (polyacetal) and PP (polypropylene)! ⁇ .
  • the POM has a disappearance start temperature of 352 ° C and a disappearance temperature power of 88 ° C.
  • the PP has a disappearance start temperature of 255 ° C and a disappearance temperature of 497 ° C.
  • the above-mentioned disappearance temperature is the disappearance temperature when the degreasing process is performed at a rate of temperature increase of 20 ° CZ time.
  • the disappearance start temperature of the binder A is lower than the disappearance start temperature of the hole forming material.
  • the binder B having a temperature higher than the disappearance start temperature of the pore forming material is employed.
  • the reference for the disappearance of the binder and the hole forming material is expressed by the decomposition start temperature and the decomposition end temperature.
  • the feature of the present invention is that the binder is formed when the hole forming material disappears. If the binder disappears in another manner, it is preferable to set the temperature and the time at which the binder actually disappears as a reference.
  • the pore-forming material does not soften the molding material having the above configuration, and is kneaded at a temperature (about 200 ° C) to form a pellet for injection molding, and then molded into a predetermined shape by an injection molding machine. .
  • molding is performed at a temperature at which the shape of the pore forming material does not change.
  • FIG. 1 shows a schematic internal structure of the injection-molded molded body 1.
  • the metal powder 3, the binder A and the binder B are distributed almost uniformly so as to surround the large pore forming material 2.
  • the force binders A and B expressing the noinders A and B in the form of particles are distributed so as to be melted and filled between the particles.
  • binder A represents a small black circle
  • binder B represents a large black circle.
  • the temperature of the degreasing furnace is increased by 20 ° CZ time.
  • the binder A starts to disappear, and the first degreasing step S103 is performed until the pore forming material starts to disappear.
  • a predetermined gap is formed between the metal particles before the pore forming material 2 starts to disappear.
  • the binder A disappears and the pore forming material 2 begins to disappear.
  • Binder starts to disappear and the second degreasing process is performed.
  • the pore forming material 2 starts to disappear at 240 ° C or higher
  • the binder B starts to disappear at about 255 ° C or higher. That is, in the second degreasing step, the above three disappearing components disappear simultaneously.
  • Figure 2 shows the state in which the above binder A has completely disappeared. In FIG. 2, for the sake of easy understanding, it is shown that all of the pore forming material 2 and the binder B are not lost, but part of them is actually lost.
  • the binder A and the hole forming material 2 are completely lost, and the holes 5 are formed.
  • the binder B is connected to the metal particles 3 in a stretched state in a slightly soft state to improve the shape retention. Further, the binder B does not cause the metal particles to fall into the holes 5 after the hole forming material has disappeared.
  • an intermediate degreased body with a shape and dimensional accuracy that does not change the relative position of the metal particles is formed.
  • the temperature is further raised to perform the third degreasing step (S105), and the binder B is removed.
  • the third degreasing step a degreased body formed from the metal particles 3 as shown in FIG. 4 is formed.
  • the degreased body is almost shrunk because the particles exist three-dimensionally in the vertical direction of the paper surface expressed as if the particles are separated from each other.
  • the temperature in the furnace is raised to a temperature equal to or higher than the sintering temperature of the metal, and a sintering step is performed to sinter the metal particles.
  • a sintering step is performed to sinter the metal particles.
  • each adjacent particle is sintered and the gap between each particle is clogged.
  • the sintered body 6 is formed. Note that the sintered body is contracted from the formed body by the amount of the binder.
  • FIG. 7 shows a mode in which the hole forming material 2 and the binder (the whole of A and B) decrease in the present embodiment.
  • the vertical axis represents the reduction rate and the horizontal axis represents the degreasing temperature.
  • a part of the binder A starts to disappear.
  • vacancy forming material 2 begins to disappear, but the rate of decrease of vacancy forming material 2 exceeds the binder at a certain temperature, and this trend continues until the vacant forming material disappears completely. Material 2 disappears before the binder.
  • a degreasing process is performed with the binder reinforced while securing the disappearance route, and even when the pore forming material is completely disappeared, Part remains.
  • the degreasing process can be advanced in a state where the shape retention of the molded body is improved.
  • binder B is configured by blending two types of binder components having different disappearance temperatures, the binder remaining after the void forming material 2 disappears rapidly. It will not disappear. Therefore, it is possible to prevent excessive stress from acting on the molded body in the process of disappearance of the binder. As a result, shape retention is ensured even after the pore forming material 2 disappears, and it is possible to prevent the molded body from being deformed.
  • Table 2 shows the blending ratio of the comparative example.
  • This comparative example shows the disappearance temperature of the pore forming material 2
  • a binder C polystyrene
  • the other blending ratios are the same as in Example 1 and will not be described.
  • the degreasing step and the sintering step are also performed in the same manner as in the above example. Note that the third degreasing step is not performed in the comparative example because noinda B is not blended.
  • the porosity of the sintered bodies formed from Example 1 and Comparative Example was measured.
  • a porous body having a porosity of about 60% corresponding to the mixing ratio of the pore forming material 2 was obtained.
  • the porosity was about 40% even though the same proportion of pore-forming materials were blended.
  • Example 1 and the sintered bodies according to Comparative Example were observed with a microscope, in Example 1, almost uniform spherical pores were formed.
  • the shape of the pores was irregularly deformed and the size was getting smaller. From this, it was clarified that a porous sintered body with high accuracy can be formed by eliminating the pore forming material while retaining the metal particles with the binder B.
  • an intermediate working step S106 can be performed after the second degreasing step S104.
  • the binder since the binder can remain after the pore forming material disappears, the strength of the porous molded body can be ensured. Therefore, various processes can be performed on the sintered body that has become porous.
  • machining or the like can be performed as in the conventional case.
  • various functional materials can be filled in the pores of the molded body in which continuous pores are formed.
  • the molded body after the second degreasing step is almost shrunk, and thus the size of the pores is also large. For this reason, it is possible to fill the intermediate with a functional substance that has been impossible in the past.
  • the filling method is not particularly limited, but since the porosity is high, the functional substance can be filled using a fluid or the like. In addition, the functional material can be filled only in the surface layer by a mechanical method.
  • the catalytic substance can be fixed to the inner walls of the pores by sintering in the sintering step. This makes it possible to fix expensive materials such as platinum efficiently inside the pores.
  • the third degreasing step S107 and the sintering step S108 are performed.
  • the pores 5 are also contracted, so that the granular material can be held in the pores so as to be free to move and not to be removed.
  • a metal oxide such as titanium oxide or a functional ceramic such as apatite can be employed.

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Abstract

L'invention concerne un procédé de production d'un aggloméré poreux. Ce procédé comprend: une étape de moulage (S102) au cours de laquelle un matériau de moulage d'aggloméré contenant un liant, un matériau en poudre frittable et un agent porogène est moulé en une forme donnée; des étapes de dégraissage (S103, S104 et S105) au cours desquelles le liant est retiré du moulage obtenu au cours de l'étape de moulage; et une étape de frittage (S108) au cours de laquelle le moulage dégraissé qui a été soumis aux étapes de dégraissage est fritté de sorte à former un aggloméré, le liant contenant un ingrédient qui disparaît à une température plus élevée que l'agent porogène, et l'agent porogène étant éliminé au cours des étapes de dégraissage, alors qu'une partie du liant est conservée. L'invention permet ainsi d'obtenir un aggloméré poreux présentant une porosité élevée et une bonne précision de forme et de dimensions. Cet aggloméré poreux peut avoir une fonction que n'ont pas les agglomérés poreux classiques.
PCT/JP2005/018850 2004-10-15 2005-10-13 Procede de production d'agglomere poreux, materiau de moulage d'agglomere poreux et agglomere poreux associe WO2006041118A1 (fr)

Priority Applications (6)

Application Number Priority Date Filing Date Title
EP05793657.7A EP1808243B1 (fr) 2004-10-15 2005-10-13 Procede de production d'agglomere poreux, materiau de moulage d'agglomere poreux et agglomere poreux associe
ES05793657T ES2738003T3 (es) 2004-10-15 2005-10-13 Proceso de producción de sínter poroso, material de moldeo de sínter poroso y sínter poroso
US11/665,017 US9272333B2 (en) 2004-10-15 2005-10-13 Method of making a porous sintered body, a compound for making the porous sintered body, and the porous sintered body
JP2006540963A JP5503838B2 (ja) 2004-10-15 2005-10-13 多孔質焼結体の製造方法、多孔質焼結成形材料及び多孔質焼結体
US14/962,466 US20160090327A1 (en) 2004-10-15 2015-12-08 Method of making a porous sintered body, a compound for making the porous sintered body, and the porous sintered body
US16/545,646 US11819917B2 (en) 2004-10-15 2019-08-20 Method of making a porous sintered body, a compound for making the porous sintered body, and the porous sintered body

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JP2004301482 2004-10-15
JP2004-301482 2004-10-15

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US11/665,017 A-371-Of-International US9272333B2 (en) 2004-10-15 2005-10-13 Method of making a porous sintered body, a compound for making the porous sintered body, and the porous sintered body
US14/962,466 Division US20160090327A1 (en) 2004-10-15 2015-12-08 Method of making a porous sintered body, a compound for making the porous sintered body, and the porous sintered body

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JP2008222500A (ja) * 2007-03-13 2008-09-25 Japan Aerospace Exploration Agency 多孔質成形体、多孔質充填成形体、多孔質成形体の製造方法及び多孔質充填成形体の製造方法
JP2010527409A (ja) * 2007-05-17 2010-08-12 ザ・ボーイング・カンパニー １７−４ｐｈスチールの金属焼結方法
WO2018230477A1 (fr) 2017-06-12 2018-12-20 三菱製紙株式会社 Gabarit de cryoconservation pour la cryoconservation de cellules ou de tissus
JP2022542020A (ja) * 2019-07-19 2022-09-29 インテグリス・インコーポレーテッド 多孔質焼結膜及び多孔質焼結膜を調製する方法
WO2022220301A1 (fr) * 2021-04-16 2022-10-20 クラレノリタケデンタル株式会社 Corps cru de zircone, corps calciné de zircone, corps fritté de zircone, et procédés respectivement de production de ces produits

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WO2006041118A1 (fr) 2004-10-15 2006-04-20 Taisei Kogyo Co., Ltd. Procede de production d'agglomere poreux, materiau de moulage d'agglomere poreux et agglomere poreux associe
EP2799166A4 (fr) * 2011-12-28 2016-06-15 Taisei Kogyo Co Ltd Corps fritté poreux et procédé de production de corps fritté poreux
JP6454265B2 (ja) * 2013-03-05 2019-01-16 太盛工業株式会社 多孔質焼結体及び多孔質焼結体の製造方法
ES2695849B2 (es) * 2017-07-05 2019-08-06 Univ Alicante Materiales espumados de poro interconectado con fases huesped, procedimiento para la preparacion de dichos materiales y usos de los mismos.
CN113828778B (zh) * 2021-09-23 2023-12-19 东睦新材料集团股份有限公司 一种水溶性粘结剂、粘结剂的制备方法及制备零件的方法

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JP2008222500A (ja) * 2007-03-13 2008-09-25 Japan Aerospace Exploration Agency 多孔質成形体、多孔質充填成形体、多孔質成形体の製造方法及び多孔質充填成形体の製造方法
JP2010527409A (ja) * 2007-05-17 2010-08-12 ザ・ボーイング・カンパニー １７−４ｐｈスチールの金属焼結方法
WO2018230477A1 (fr) 2017-06-12 2018-12-20 三菱製紙株式会社 Gabarit de cryoconservation pour la cryoconservation de cellules ou de tissus
JP2022542020A (ja) * 2019-07-19 2022-09-29 インテグリス・インコーポレーテッド 多孔質焼結膜及び多孔質焼結膜を調製する方法
WO2022220301A1 (fr) * 2021-04-16 2022-10-20 クラレノリタケデンタル株式会社 Corps cru de zircone, corps calciné de zircone, corps fritté de zircone, et procédés respectivement de production de ces produits

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EP1808243B1 (fr) 2019-03-20
US20090202821A1 (en) 2009-08-13
JP5503838B2 (ja) 2014-05-28
EP1808243A4 (fr) 2010-07-14
ES2738003T3 (es) 2020-01-17
US20160090327A1 (en) 2016-03-31
US20190367419A1 (en) 2019-12-05
US11819917B2 (en) 2023-11-21
US9272333B2 (en) 2016-03-01
EP1808243A1 (fr) 2007-07-18
JPWO2006041118A1 (ja) 2008-08-07

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